Section 12 Adjustment, Repair and Replacement

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1 Section 12 Adjustment, Repair, and Replacement Page 12-1 Section 12 Adjustment, Repair and Replacement Section Contents Page Overview Belts Belt Guard Removal/Installation Belt Removal/Installation Automatic Belt Tensioner Removal/Installation Coolant Coolant Heat Exchanger Removal/Installation Coolant Heater Removal/Installation Coolant Hose Removal/Installation Raw Water Pressure Regulator Removal/Installation Raw Water Solenoid Valve Removal/Installation Water Temperature Gauge Removal/Installation Coolant Temperature Sender Removal/Installation Coolant Temperature Switch Removal/Installation Coolant Thermostat Removal/Installation Coolant Thermostat Tests Coolant Water Pump Removal/Installation Coolant Filter Assembly Removal/Installation Electrical Alternator Checks and Testing Alternator Removal/Installation Alternator Bracket Removal/Installation Battery Isolator Removal/Installation Engine Harness Removal/Installation Voltmeter Removal/Installation Battery Testing Battery Removal/Installation Check Battery Cables and Connections Starter Motor Assembly Removal/Installation Crank Solenoid Assembly Removal/Installation Control Panel Fuse Replacement

2 Page Section Contents (Cont) Section 12 Adjustment, Repair, and Replacement Page Exhaust Exhaust Manifold Removal/Installation Exhaust Restriction Measurement Exhaust Shield Removal/Installation Fuel CAPS Fuel System Overview Fuel Pump Delivery Valve Removal/Installation Fuel Pump Gear Pump Check Fuel Pump Gear Pump Removal/Installation Adjust Fuel Pump Timing Fuel Lift Pump Check Fuel Lift Pump Removal/Installation CAPS Fuel Injection Pump Rotor Removal/Installation Injection Control Valve Removal/Installation Pumping Control Valve Tests Rate Shape Snubber Removal/Installation Fuel Pump Distributor Inlet Fitting Fuel Pump Accumulator Module Fuel Pump Distributor and Injection Control Valve Module Fuel Pump Cam Housing Module Fuel Pump Gear Pump Module Check Fuel Pump Gear Pump Module Removal/Installation Fuel Pump Rate Shape Tube Fuel Pump Head Outlet Fitting Fuel Pump Head Checks Fuel Pump Head Removal/Installation Fuel Pump Actuator Housing Fuel Injection Pump Removal/Installation Fuel Cooled ECM Cooling Plate Removal/Installation Measure Fuel Drain Line Restriction Fuel Drain Lines Removal/Installation Spin-On Type Fuel Filter Measure Fuel Inlet Restriction

3 Section 12 Adjustment, Repair, and Replacement Page 12-3 Section Contents (Cont) Low Pressure Fuel Supply Lines Removal/Installation Fuel Injectors Removal/Installation High Pressure Injector Supply Lines Removal/Installation Head Mounted Fuel Connector Fuel Pump Air Bleed Line Fuel Rail Fuel Pressure Relief Valve Fuel Rail High Pressure Fitting Air in Fuel Fuel Filter Head Bracket Removal/Installation Fuel Pump Removal/Installation Intake Air Intake Air Filter Removal/Installation Air Crossover Removal/Installation Air Inlet Connection Removal/Installation Air Leaks, Air Intake and Exhaust Systems Air Intake Restriction Removal/Installation Turbocharger Checks Turbocharger Removal/Installation Turbocharger Oil Drain Line Removal/Installation Turbocharger Oil Supply Line Removal/Installation Turbocharger Wastegate Actuator Checks Turbocharger Wastegate Actuator Removal/Installation Turbocharger Wastegate Valve Body Inspection Measure Intake Manifold Pressure Air Intake Connection Removal/Installation Air Intake Manifold Cover Removal/Installation Charge Air Cooler (CAC) Removal and Installation Clean the Charge Air Cooler Inspect Charge Air Cooler (CAC) Charge Air Cooler Pressure Test Charge Air Cooler Leak Test Charge Air Cooler (CAC) Temperature Differential Test Page

4 Page Section Contents (Cont) Section 12 Adjustment, Repair, and Replacement Page Oil Fill and Drain Lubricating Oil Lubricating Oil Cooler Removal/Installation Lubricating Oil Dipstick Tube Removal/Installation Lubricating Oil Dipstick Calibration Lubricating Oil Filter Removal/Installation Lubricating Oil Bypass Valve Removal/Installation Lubricating Oil Filter Head Removal/Installation Lubricating Oil High Pressure Relief Valve Removal/Installation Lubricating Oil Pan Removal/Installation Lubricating Oil Pressure Regulator Removal/Installation Lubricating Oil Pump Removal/Installation Lubricating Oil Suction Tube Removal/Installation Lubricating Oil and Filter Analysis Oil Pressure Switch Removal/Installation Oil Pressure Sender Removal/Installation Oil Pressure Gauge Removal/Installation Speed Speed Sensor Removal/Installation Tachometer Removal/Installation Overspeed Switch Removal/Installation Tachometer Calibration

5 Section 12 Adjustment, Repair, and Replacement Page 12-5 Section Contents (Cont) Page ECM Primary ECM Removal/Installation Secondary ECM Removal/Installation ECM Harness Removal/Installation ECM Engine Speed Sensor ECM Engine Position Sensor ECM Oil Pressure Sensor ECM Boost Pressure Sensor ECM Coolant Temperature Sensor ECM Fuel Pressure Sensor ECM Fuel Temperature Sensor ECM Ambient Air Pressure Sensor ECM Air Temperature Sensor

6 Page Section 12 Adjustment, Repair, and Replacement Coverage Overview This section of this manual addresses the Adjustment, Repair, and Replacement of Cummins NPower Fire Pump Engine components. Work this manual with the associated base engine troubleshooting and repair manuals. Base engine components are addressed in Cummins Manual No , ISC, QSC8.3, ISL, and QSL9 Troubleshooting and Repair Manual. The electronic engine control module and associated components are addressed in Cummins Manual No , ISC, ISCe, ISL, QSC8.3, and QSL9 Electronic Control System Troubleshooting and Repair Manual. Refer to Service Literature Section 13 for additional information about these manuals. Requirements Satisfy all code requirements or local regulations necessary to remove the fire pump from service. This may require contacting the local fire department or other authority. Obtain the required tools and supplies for the intended service. If fluids are to be drained, get appropriate containers. Dispose of any waste fluids or removed components in accordance with applicable environmental requirements. Ensure that the area is prepared for the intended service. When work is completed, ensure that the fire pump is operational and correctly aligned for service. As required, notify the local fire department or other authority. Maintenance must be performed by trained, experienced technicians. Refer to Service Assistance Section 14 for qualified service assistance.

7 Section 12 Adjustment, Repair, and Replacement Page 12-7 CFP08E Series Prepare Belt Guard Removal/Installation WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50 C [122 F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Place the fire protection system in a safe mode for engine service. Place the AUTO/MANUAL rocker switch in the MANUAL position. Disconnect or isolate the coolant heater power supply. Disconnect and insulate the Contactor to Starter Cable (Cummins Fire Power Part No 9762) from the starter (Refer to Drawing 9767 in Section 18).

8 Page 12-8 Section 12 Adjustment, Repair, and Replacement CFP08E Series Belt Guard Removal/Installation (Cont) Ensure that the engine and engine coolant is cool in order to avoid burns. Remove the engine coolant pressure cap. Drain the engine coolant system. Refer to Drain and Flush Coolant System in Section 8. Remove the Lower Engine Coolant and Fill Hose from the heat exchanger. Remove Remove the three bolts and the belt guard.

9 Section 12 Adjustment, Repair, and Replacement Page 12-9 CFP08E Series Belt Guard Removal/Installation (Cont) Install NOTE: Install only Cummins approved replacement belt guard (Cummins Fire Power Part No. 9820) or equivalent. When other work is completed, install the belt guard using the three bolts. Torque as per Capscrew Markings and Torque Values in Section 15. Close coolant drain valve. Refill the engine coolant. Refer to Drain and Flush Coolant System in Section 8. Install the coolant system pressure cap. Reconnect the coolant heater power supply.

10 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Belt Guard Removal/Installation (Cont) Reconnect the Contactor to Starter Cable (Cummins Fire Power Part No 9762) at the starter (Refer to Drawing 9767 in Section 18). NOTE: Start the engine and do a quick check for leaks. If any coolant leaks are observed, stop the engine, repair the leak, check coolant level, then restart the engine. Start the engine. Refer to Normal Local Starting Procedure in Section 3. Check for and repair any coolant leaks. Ensure that repairs are completed satisfactorily. Stop the engine.

11 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Prepare Do the preparatory steps and remove the Belt Guard. Refer to Belt Guard Removal / Installation in this section. Belt Removal/Installation Remove NOTE: The belt tensioner is spring-loaded and must be pivoted away from the drive belt. Pivoting in the wrong direction can result in damage to the belt tensioner. Lift the tensioner to remove the drive belt. Install NOTE: The belt tensioner is spring-loaded and must be pivoted away from the drive belt. Pivoting in the wrong direction can result in damage to the belt tensioner. Service Tip: If difficulty is experienced installing the drive belt (i.e., the belt seems too short), position the belt over the grooved pulleys first then while holding the tensioner up, slide the belt over the water pump pulley. NOTE: Install only Cummins approved replacement v-ribbed belts (Cummins Part No ) or equivalent. Lift and hold the belt tensioner. Install the drive belt and release the tensioner. Follow-Up When work is completed, install the Belt Guard and do the listed follow up steps. Refer to Belt Guard Removal/Installation in this section. Check that the drive belt operates without unusual noises.

12 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Prepare Automatic Belt Tensioner Removal/Installation Do the preparatory steps and remove the Belt Guard. Refer to Belt Guard Removal/Installation in this section. Remove the Drive Belt. Refer to Belt Removal/ Installation in this section. Remove Remove the belt tensioner from the bracket. Install NOTE: Install only Cummins approved replacement belt tensioner (Cummins Part No ) or equivalent. Install the belt tensioner and cap screw. Torque Value: 43 N m [32 ft-lb] Follow-Up When work is completed, install the Drive Belt. Refer to Belt Removal/Installation in this section. When work is completed, install the Belt Guard and do the listed follow up steps. Refer to Belt Guard Removal/Installation in this section. Check that the drive belt operates without unusual noises.

13 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Prepare Coolant Heat Exchanger Removal/Installation WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50 C [122 F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Place the fire protection system in a safe mode for engine service. Place the AUTO/MANUAL rocker switch in the MANUAL position. Disconnect or isolate the coolant heater power supply. Disconnect and insulate the Contactor to Starter Cable (Cummins Fire Power Part No 9762) from the starter (Refer to Drawing 9767 in Section 18).

14 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Heat Exchanger Removal/Installation (Cont) Ensure that the engine and engine coolant is cool in order to avoid burns. Remove the engine coolant pressure cap. Drain the engine coolant system. Refer to Drain and Flush Coolant System in Section 8. Remove the Upper Engine Coolant Hose from the heat exchanger. Remove the Lower Engine Coolant and Fill Hose from the heat exchanger. Close the Raw Water Manifold Bypass Line Outlet Isolation Valve. Close the Raw Water Manifold Normal Line Outlet Isolation Valve.

15 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Coolant Heat Exchanger Removal/Installation (Cont) Remove the 1 NPT raw water inlet piping from the charge air cooler to the heat exchanger. (Refer to Drawing 9595 in Section 18 for raw water supply piping details.) Also, remove any customer-supplied raw water outlet fittings. Save these components for reuse. Pressure Test NOTE: This test is required if internal leakage in the heat exchanger is suspected. It may be performed prior to the removal from the engine. NOTE: Use teflon tape or other pipe sealant when installing the test setup in order to prevent leaks. Install a 1-1/4 NPT pipe plug at the raw water outlet of the heat exchanger. Install a pressure test setup with 700 kpa [100 psi] pressure gauge at the 1 NPT raw water inlet to the heat exchanger. NOTE: There should be no detectable decrease in the pressure reading for the duration of the test. Apply air pressure at 621 kpa [90 psig]. Isolate the pressure source and monitor the pressure gauge for 5 minutes. After testing, release the pressure. Remove the pipe plug and the test setup. If leakage is detected, the heat exchanger must be replaced.

16 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Heat Exchanger Removal/Installation (Cont) Remove Provide temporary support for the coolant heat exchanger in order to avoid dropping it. Remove the four back sets of nuts, washers, and bolts at the heat exchanger mounting clamps. Remove the heat exchanger and clamps from the engine. Disassemble If required for replacement, remove the two front sets of nuts and bolts at the coolant heat exchanger clamps. If required for replacement, remove the zinc plug and other pipe fittings from the heat exchanger. Assemble NOTE: Use teflon or other pipe sealant when installing threaded pipe fittings. If missing, install the zinc plug (Cummins Fire Power Part No. 9750) and brass fitting (Cummins Fire Power Part No. 9751) in the bottom of the heat exchanger. If missing, install the pipe fittings removed from the original heat exchanger. Refer to Drawing 8944 in Section 18 for component information. If removed, position the two clamps on the heat exchanger and install the two front sets of nuts and bolts at the coolant heat exchanger clamps. Do not tighten at this time. Refer to Drawing 8944 in Section 18 for component information.

17 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Coolant Heat Exchanger Removal/Installation (Cont) Install Provide support for the coolant heat exchanger in order to avoid dropping it. Position the heat exchanger and clamps on the engine s mounting bracket and start the four bolts. Start the nut and washers on the four bolts. Align the heat exchanger with the required hose connections and tighten the four back sets of clamp fasteners. Tighten the two front sets of clamp fasteners. Follow-Up Install the Upper Engine Coolant Hose at the heat exchanger. Install the Lower Engine Coolant and Fill Hose at the heat exchanger. Install the 1 NPT raw water inlet piping from the charge air cooler to the heat exchanger. (Refer to Drawing 9595 in Section 18 for raw water supply piping details.) Also, install any customer-supplied raw water outlet fittings.

18 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Heat Exchanger Removal/Installation (Cont) Close coolant drain valve. Refill the engine coolant. Refer to Drain and Flush Coolant System in Section 8. Install the coolant system pressure cap. Reconnect the coolant heater power supply. Reconnect the Contactor to Starter Cable (Cummins Fire Power Part No 9762) at the starter (Refer to Drawing 9767 in Section 18). NOTE: Start the engine and do a quick check for leaks. If any coolant leaks are observed, stop the engine, repair the leak, check coolant level, then restart the engine. If no leaks are present, promptly establish raw water flow through the heat exchanger. Start the engine. Refer to Normal Local Starting Procedure in Section 3. Check for and repair any coolant leaks.

19 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Coolant Heat Exchanger Removal/Installation (Cont) CAUTION When establishing raw water flow, ensure that the raw water pressure does not exceed 414 kpa (60 psig) at the heat exchanger. Adjust the pressure regulators as required. Slowly open the Raw Water Manifold Bypass Line Outlet Isolation Valve. Observe raw water flow through the heat exchanger. Adjust the bypass pressure regulator if required. Close the Raw Water Manifold Bypass Line Outlet Isolation Valve. CAUTION When establishing raw water flow, ensure that the raw water pressure does not exceed 414 kpa (60 psig) at the heat exchanger. Adjust the pressure regulators as required. Slowly open the Raw Water Manifold Normal Line Outlet Isolation Valve. Observe raw water flow through the heat exchanger. Adjust the normal pressure regulator if required. NOTE: If temperature does not stabilize, stop the engine and refer to Coolant Temperature Above Normal or Coolant Temperature Below Normal (Engine Running) in Troubleshooting Section 17. Check that engine operating temperature stabilizes between about 82 and 93 o C [180 and 200 o F]. Check that no coolant hoses are collapsed. When temperature has stabilized, stop the engine. Ensure that repairs are completed satisfactorily.

20 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Heat Exchanger Removal/Installation (Cont) WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50 C [120 F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Check the coolant level. Refer to Check Coolant Level in Section 5. Add coolant if necessary. Place the AUTO/MANUAL rocker switch in the AUTO position. Return the fire protection system to operating status.

21 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Prepare Coolant Heater Removal/Installation WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50 C [122 F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Place the fire protection system in a safe mode for engine service. Place the AUTO/MANUAL rocker switch in the MANUAL position. Disconnect or isolate the coolant heater power supply. Disconnect and insulate the Contactor to Starter Cable (Cummins Fire Power Part No 9762) from the starter (Refer to Drawing 9767 in Section 18).

22 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Heater Removal/Installation (Cont) Ensure that the engine and engine coolant is cool in order to avoid burns. Remove the engine coolant pressure cap. Drain the engine coolant system. Refer to Drain and Flush Coolant System in Section 8. NOTE: Collect the remainder of the coolant in the heater hoses. NOTE: Refer to Drawing 8941 in Section 18 for detailed component information. Remove the Upper Coolant Heater Hose. Remove the Lower Coolant Heater Hose. Remove Remove the two capscrews, washers, bracket, and coolant heater. Refer to Drawing 8941 in Section 18 for detailed component information. If required, remove the nuts, bolts, washers and mounting bracket from the coolant heater.

23 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Coolant Heater Removal/Installation (Cont) Install If missing, install the nuts, bolts, washers and mounting bracket on the coolant heater. Refer to Drawing 8941 in Section 18 for detailed component information. Position the coolant heater and mounting bracket and start the two bolts with washers. Torque the two bolts on the mounting bracket as per Capscrew Markings and Torque Values in Section 15. Follow-Up NOTE: Refer to Drawing 8941 in Section 18 for detailed component information. Install the Upper Coolant Heater Hose. Install the Lower Coolant Heater Hose. Close the coolant drain valve.

24 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Heater Removal/Installation (Cont) Refill the engine coolant. Refer to Drain and Flush Coolant System in Section 8. Install the coolant system pressure cap. Reconnect the Contactor to Starter Cable (Cummins Fire Power Part No 9762) at the starter (Refer to Drawing 9767 in Section 18). NOTE: Start the engine and do a quick check for leaks. If any coolant leaks are observed, stop the engine, repair the leak, check coolant level, then restart the engine. Start the engine. Refer to Normal Local Starting Procedure in Section 3. Check for and repair any coolant leaks. Stop the engine. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50 C [120 F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Check the coolant level. Refer to Check Coolant Level in Section 5. Add coolant if necessary.

25 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Coolant Heater Removal/Installation (Cont) Reconnect the coolant heater power supply. Observe that the coolant temperature cools down but stabilizes. Check that the engine block remains warm to the touch. Place the AUTO/MANUAL rocker switch in the AUTO position. Return the fire protection system to operating status.

26 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Hose Removal/Installation Identify hose clamps and add manufacturer s torque value. NOTE: This section addresses all coolant tubes and hoses. Only remove those coolant hoses that are necessary. It is not required to remove both ends of the hose for the replacement of other components. Use the following sections as applicable: Prepare Remove the Upper Engine Coolant Hose Remove the Lower Engine Coolant and Fill Hoses Remove the Upper Coolant Heater Hose Remove the Lower Coolant Heater Hose Remove the Coolant Vent Hose Inspect Install the Upper Engine Coolant Hose Install the Lower Engine Coolant and Fill Hoses Install the Upper Coolant Heater Hose Install the Lower Coolant Heater Hose Install the Coolant Vent Hose Follow-Up

27 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Coolant Hose Removal/Installation (Cont) Prepare WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50 C [122 F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Place the fire protection system in a safe mode for engine service. Place the AUTO/MANUAL rocker switch in the MANUAL position. Disconnect or isolate the coolant heater power supply. Disconnect and insulate the Contactor to Starter Cable (Cummins Fire Power Part No 9762) from the starter (Refer to Drawing 9767 in Section 18).

28 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Hose Removal/Installation (Cont) Ensure that the engine and engine coolant is cool in order to avoid burns. Remove the engine coolant pressure cap. Drain the engine coolant system. Refer to Drain and Flush Coolant System in Section 8. Remove the Upper Engine Coolant Hose NOTE: Refer to Assembly Drawing 8944 in Section 18 for detailed construction. Loosen the hose clamp at the heat exchanger. Loosen the hose clamp at the engine. Pull the hose from the heat exchanger and engine. Remove the Lower Engine Coolant and Fill Hoses NOTE: Refer to Assembly Drawing 8944 in Section 18 for detailed construction. Remove the nuts and U-bolt supporting the lower engine coolant hose. Loosen the fill hose clamp at the heat exchanger. Loosen the engine coolant hose clamp at the heat exchanger. Loosen the engine coolant hose clamp at the engine. Pull the hoses from the heat exchanger and engine. If required for replacement, disassemble the components.

29 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Coolant Hose Removal/Installation (Cont) Remove the Upper Coolant Heater Hose NOTE: Refer to Assembly Drawing 8941 in Section 18 for detailed construction. NOTE: Be prepared to collect the residual coolant that may drain from the hose. Loosen the hose clamp at the engine. Loosen the hose clamp at the coolant heater. Pull the hose and tubing from the connections. Disassemble additional components if this is required for inspection or repairs. Remove the Lower Coolant Heater Hose NOTE: Refer to Assembly Drawing 8941 in Section 18 for detailed construction. NOTE: Be prepared to collect the residual coolant that may drain from the hose. Loosen the hose clamp at the engine. Loosen the hose clamp at the coolant heater. Pull the hose and tubing from the connections. Disassemble additional components if this is required for inspection or repairs. Remove the Coolant Vent Hose NOTE: Refer to Assembly Drawing 9543 in Section 18 for detailed construction. Loosen the flair fitting at the coolant heat exchanger. Loosen the flair fitting at the engine. Pull the hose from the connections.

30 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Hose Removal/Installation (Cont) Inspect NOTE: Inspect the cooling system hoses and hose connection for leaks or deterioration. Particles of deteriorated hose can be carried through the cooling system and slow or partially stop circulation. Inspect the hoses and hose connections. Replace any hoses or clamps that are damaged. Install the Upper Engine Coolant Hose CAUTION Do not re-install worn or damaged hoses or corroded clamps. NOTE: Refer to Assembly Drawing 8944 in Section 18 for detailed construction. Position the hose clamps on the hose. Push the hose onto the heat exchanger and engine connections. Tighten the hose clamp at the heat exchanger. Tighten the hose clamp at the engine.

31 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Coolant Hose Removal/Installation (Cont) Install the Lower Engine Coolant and Fill Hoses CAUTION Do not re-install worn or damaged hoses or corroded clamps. NOTE: Refer to Assembly Drawing 8944 in Section 18 for detailed construction. Position the hose clamps on the hoses. Push the hose on the connections at the heat exchanger and engine. Position and tighten the lower engine coolant hose clamp at the engine. Position and tighten the lower engine coolant hose clamp at the heat exchanger. Position and tighten the upper fill hose clamp at the heat exchanger. Install the nuts and U-bolt supporting the lower hose. Tighten the capscrew as per Capscrews Markings and Torque Values in Section 15. Install the Upper Coolant Heater Hose CAUTION Do not re-install worn or damaged hoses or corroded clamps. NOTE: Refer to Assembly Drawing 8941 in Section 18 for detailed construction. Position the hose clamps on the hoses. Push the hose on the connections at the coolant heater and the engine. Position and tighten the lower engine coolant hose clamp at the engine. Position and tighten the lower engine coolant hose clamp at the coolant heater.

32 Page Section 12 Adjustment, Repair, and Replacement CFP08E Series Coolant Hose Removal/Installation (Cont) Install the Lower Coolant Heater Hose CAUTION Do not re-install worn or damaged hoses or corroded clamps. NOTE: Refer to Assembly Drawing 8941 in Section 18 for detailed construction. Position the hose clamps on the hoses. Push the hose on the connections at the coolant heater and the engine. Position and tighten the lower engine coolant hose clamp at the engine. Position and tighten the lower engine coolant hose clamp at the coolant heater. Install the Coolant Vent Hose CAUTION Do not re-install worn or damaged hoses or corroded clamps. NOTE: Refer to Assembly Drawing 9543 in Section 18 for detailed construction. Connect the hose flair connector at the heat exchanger. Connect the hose flair connector at the engine coolant vent connection. Follow-Up Close the coolant drain valve.

33 Section 12 Adjustment, Repair, and Replacement Page CFP08E Series Coolant Hose Removal/Installation (Cont) Refill the engine coolant. Refer to Drain and Flush Coolant System in Section 8. Install the coolant system pressure cap. Reconnect the coolant heater power supply. Reconnect the Contactor to Starter Cable (Cummins Fire Power Part No 9762) at the starter (Refer to Drawing 9767 in Section 18). NOTE: Start the engine and do a quick check for leaks. If any coolant leaks are observed, stop the engine, repair the leak, check coolant level, then restart the engine. Start the engine. Refer to Normal Local Starting Procedure in Section 3. Check for and repair any coolant leaks. Check that engine operating temperature stabilizes between about 82 and 93 o C [180 and 200 o F]. Check that no coolant hoses are collapsed. When temperature has stabilized, stop the engine. Ensure that repairs are completed satisfactorily.

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